Method of making engine rocker arms



Nov. 11, 1952 J. M. LEAKE METHOD OF MAKING ENGINE ROCKER ARMS Filed June 25, 1949 FIG. .9 I6

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Patented Nov. 11, 1952 UNITED STATES PATENT OFFICE METHOD OF MAKING ENGINE ROCKER ARMS 2 Claims.

The object of this invention is to make a rocker arm out of plate metal. The particular rocker arm to which the invention is directed is the one employed in connection with the valve operating mechanism in an internal combustion engine.

My former stamped engine rocker arm disclosed in Patent No. 2,176,083 provided many advantages over the old style cast and forged rocker arms. This rocker arm provides an arm member consisting of layers welded together. In this type of construction some of the desirable qualities of the sheet metal are lost in the welding process.

My improved engine rocker arm provides a single layer arm member formed from a strip of preformed plate metal. My improved engine rocker arm combines the advantages of the old style cast and forged engine rocker arms with the advantages of the stamped sheet metal rocker arm without losing any of the desirable qualities of the sheet metal.

One object of my invention is to provide an engine rocker arm that is light in weight.

Another object of my invention is to provide an engine rocker arm that provides a solid one piece arm member made of plate metal.

Another object of my invention is to provide an engine rocker arm that eliminates any welding or brazing in the arm assembly.

Another object of my invention is to provide oil passageways that do not require welding or brazing.

Another object of my invention is to provide an engine rocker arm that requires the assembly of a minimum number of parts.

Another object of my invention is to provide an engine rocker arm that requires a minimum of working of the plate metal of which the arm is formed.

Another object of my invention is to construct an engine rocker arm in which all of the desirable qualities of the plate metal are retained.

Another object of my invention is to provide an engine rocker arm that is strong, durable and inexpensive.

With these and other objects in view, my invention consists in the construction, combination and arrangements of parts of my improved device as described in the specification, claimed in the claims and illustrated in the accompanying drawings.

In the drawings:

Fig. l is a view of a portion of the preformed strip of plate metal from which the arm member of my improved engine rocker arm is made.

Fig. 2 is a sectional view taken along line 2-2 of Fig. 1.

Fig. 3 is a front elevation of the blank stamped or cut from the preformed strip of plate metal shown in Fig. 1.

Fig. 4 is a front elevation showing indentations formed in the one enlarged end of the arm member.

Fig. 5 is a. sectional view taken along line 55 of Fig. 4.

Fig. 6 is a front elevation, partially in section, showing the vertical hole pierced in the arm member.

Fig. 7 is a front elevation of the tubular hub member before it is assembled in the arm member.

Fig. 8 shows the metal plate arm member with the hub member assembled in position.

Fig. 9 is a sectional view taken along line 9-9 of Fig. 8.

Fig. 10 is a front elevation of the completely assembled engine rocker arm.

Referring to the drawings in more detail, in Fig. l I have shown a portion I of a preformed plate metal strip. Fig. 2 is a sectional view showing the flat mid section 2 and the enlarged rounded edges 3 and 4 of the preformed plate metal strip I. In the first operation the blank 5 is stamped from the preformed metal strip I. In the same operation the annular hole 6 is pierced intermediate the enlarged rounded end portions I and 8 of the blank 5. Notches 9 are formed in the edges of the annular hole 6.

The indentations I0 and II are pressed in the rounded end I of the blank 5. The indentations I0 and II are in axial alignment. At the same time a smaller indentation I2 is formed directly above the annular hole 6.

The enlarged rounded end I is then pierced to form an annular vertical aperture I3 shown in Fig. 6. The indentations I I] and II reduce the length of the hole that has to be pierced to form the aperture I3. The vertical aperture I3 is then threaded so that a male threaded contacting bearing can be adjustably secured in the enlarged end I of the arm member.

The blank 5 which has been processed as described above provides the arm member I4 of my improved engine rocker arm,'as shown in Fig. 10.

A tubular member I5 of predetermined length is inserted in the aperture 6. The tubular member I5 is then upset on both sides of the arm member I4 as shown in Fig. 9. This is done by applying pressure from both ends of the tubular member I5 and at the same time confining the inner surface of the tubular member and also confining the ends of the tubular member near the end portions. The pressure applied on both ends of the tubular member l5 causes the metal to flow. The only place the tubular member can expand is the portion near the two sides of the arm member M which is not confined. The tubular member l5 then expands adjacent the arm member 14 to provide "annular upset flanges I6. In the upsetting processmetal from the tubular member I5 is forced into the notches 9, thus preventing rotary motion of the tubular hub member [5 in the arm member M. The annular'flanges l6 prevent endwise motion of the hub member IS in the arm member [4. I

A tubular bushing or bearing member" I! is pressed into the hub member 15. An oilpassageway I8 is provided by piercing or drilling a hole from the indentation l8 downward through the arm member M, the hub I5 and the bushing H.

An adjust'able'contacting bearing 19 is secured in the threaded aperture l3 and is locked mp0- s'ition-by a lock nut 20.

The under surface 2 I of the enlarged 'rounded end 8 of the arm member hardened to resist wear. The hardening is preferably done before the-hub 'l5'is sec'ured'in the arm member 14.

By this method of manufacture 'a simple plate metal rocker arm, for the purpose described, is provided. It will be-noted thatnobrazing' or welding isrequired inmy improved processwhich destroys the strength, grain and other desirable characteristics oi'plate or sheet metal. Furthermore no upsetting, compacting or expandingis required in the processing of the arm member 14. 'Therefore all of thedesirable qualities-of the plate metal are retained.

It will'be noted that oil cannot leakfrom the oil passage l8. Oil leakage from this oil passageway has been one of the major objections to the laminated arm member as disclosed in my Patent No. 2,176,083.

The contacting surface 2! of-my improved engine rocker arm may be engagedby the valve stem and the adjustable contacting bearing l9 may engage the push'rod in the valve operating mechanism of an internal combustion engine.

The detailsand arrangements herein shown and described may be varied by askilled-mechanic without departing from the scope of my invention as expressed in the claims; For-example thehub l5 and the bushing I! may bemade of r a single tubular member which-has a -layer of steel or I4 is preferably one ofsaid-rounded' edge portions, threading said aperture, piercing a horizontal aperture in said arm member intermediate said rounded edge portions, forming a plurality of notches around the periphery-of said horizontal aperture on each side of said arm member, inserting a tubular hub member in said horizontal aperture and upsetting said hub member adjacent both sides of said arm member and-simultaneouslyupsettingportions of saidhubmember into said-*notcheson each side of said armmember.

I 2. The method' of makingan-enginerocker arm which consists in forminga: horizontal aperture intermediate-the ends of a preformed arm member adapted to provide a plurality of:-'contacting bearings, forming a plurality of notches in said arm member-around -the periphery of said-aperture terminating ateachside-ofsaid arm member, inserting a tubular hub member in said aperture, upsettingsaid hub member intermediateits ends adjacent both sides of said arm member and at the same-time simultaneously upsetting portions of said hub memberinto'said notches oneach side of said arm member.

JAMES .M. LEAKE.

"REFERENCES CITED The following #references are of record in the file of-this patent:

lilN-ITED STATES PATENTS Number Name Date i3'2 l 990 Evans Aug.25',1'885 656,712 "Bidle Aug..28; 19OO 1,278,195 Noaok Sept: 10, 1918 1,634,561 Shapiro July-5,1927 1,793,874 Sk'illman 'Feb.' 24; 1931 1,341,920 a Smith 'Jan. 19,"1$32 138 3 906 Hasselquist Oct; 25,1932 2,120,118 Smith Jnne.7, 1938 2,176,083 Leake Oct. 17;1939 2,239,203 Rendleman- Apr. '22; I941 

